service repair manual

1. K1048003E Shop Manual
Copyright 2008 DOOSAN
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Shop Manual
K1048003E
Serial Number 5001 and Up
DX225LC

2. Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Safety....................................................................... SP000907
Specifications
Specification for DX225LC.................................................................. SP001616
General Maintenance
General Maintenance Procedures ...................................................... SP000016
Standard Torques ................................................................................ SP000813
Upper Structure
Cabin .................................................................................................... SP000943
Counterweight....................................................................................... SP001617
Fuel Tank............................................................................................. SP001005
Fuel Transfer Pump ............................................................................ SP000021
Swing Bearing...................................................................................... SP000022
Swing Reduction Gear ........................................................................ SP001618
Lower Structure and
Chassis
Track Assembly ................................................................................... SP001619
Engine and Drive Train
Drive Coupling (Main Pump) .............................................................. SP000912
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ........... SP000913
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)........................................................................... SP001620

3. Table of Contents
Page II
Cylinders............................................................................................... SP000914
Swing Motor......................................................................................... SP000194
Travel Motor......................................................................................... SP001621
Gear Pump........................................................................................... SP000931
Main Control Valve.............................................................................. SP001024
Axial Piston Pump............................................................................... SP000932
PTO Server.......................................................................................... SP000933
Remote Control Valve (Work Lever / Joystick) ................................ SP001646
Travel Control Valve (with Damper) .................................................. SP001647
Solenoid Valve Assembly.................................................................... SP001622
Breaker EPPR Valve (Opt)................................................................. SP000192
Hydraulic Schematic (DX225LC) ........................................................ SP001689
Electrical System
Electrical System ................................................................................. SP001645
Electrical Schematic (DX225LC)......................................................... SP001690
Attachments
Boom and Arm .................................................................................... SP000937
Bucket................................................................................................... SP000939

4. SP001621Travel Motor
Page 30
Disassembly Instructions
General Cautions
1. Spread s rubber or vinyl cover on the work bench.
2. When disassembling the traveling motor, provide a match
mark on the mating face or each part.
3. Arrange the detached parts to prevent them from being
damaged or lost.
4. The disassembled seals must be replaced with new ones
as a rule even if they are free from damage.
For disassembly, therefore, prepare new seals in advance.
Disassembly procedure
1. When inspecting or repairing the TM motors, use the
disassembling procedures described below.
2. Numerals in brackets ( ) following the part name denote the
part numbers used in the operation manual.
3. Prior to disassembly, install the TM motor on a inversion
working bench.
4. Fit the TM motor on the turn-over working die to start its
disassembly.
Disassembling the Reduction gear part
1. Remove plugs (128) (3EA) and drain the reduction gear oil.
NOTE: Remove the cover(123), after hook it, fit the
eye-bolt in a screw holl for use of the plug(128).
If it's impossible, please remove the cover using
the rod.
2. Loosen socket bolts (124) (16EA) and remove the cover
(123).
NOTE: You can have difficulty removing it because
loctite is spread in the socket bolt(124).
• Hexagon wrench 8, 10
Figure 16

5. SP001621
Page 31
Travel Motor
3. Remove drive gear (121).
4. Remove carrier no.1 assembly.
NOTE: Carrier no. 1 assembly consists of planetary
gear (117), needle bearing (118), shaft bearing
(107), carrier (134) thrust washer (131), spring
pin (122).
5. Dissembling the carrier no. 1 assembly.
A. Drive spring pins (122) into shaft bearing (R) (107).
NOTE: Please don’t remove if repair is not
necessary.
Do not reuse the spring pin (122).
B. Remove shaft bearing (R) (107), planetary gears (R)
(117), thrust washer (R) (131), needle bearings (118)
and thrust washer (R) (131).
Figure 17
Figure 18
Figure 19
Figure 20

6. SP001621Travel Motor
Page 32
6. Remove sun gear (114).
NOTE: Snap ring (115) is assembled in sun gear (114).
Do not remove it if not necessary.
7. Remove carrier no.2 assembly.
NOTE: Remove it using a crane after M10 eye bolt is
assembled.
8. Drive spring pins (110) into shaft bearing (F) (113).
NOTE: Do not resue the spring pin (110).
9. Remove shaft bearing (113) (4EA).
Figure 21
Figure 22
Figure 23
Figure 24

7. SP001621
Page 33
Travel Motor
10. Remove the thrust washer (F) (109), planetary gears (F)
(108), needle bearings (111), floating bush (112) from
carrier no. 2 (103).
NOTE: Each part consists of the 1ST.
11. Take off lock shim plate (136) by hammering on chisel or
on similar tool placed at parting surface.
12. Remove the hub[105] from the spindle (101).
NOTE: Remove it using a crane after M16 eye bolt is
assembled at the hub (105).
13. Remove the distance piece[106] from the spindle (101).
Figure 25
Figure 26
Figure 27
Figure 28

8. SP001621Travel Motor
Page 34
14. Remove the floating seal (101) from the hub[105] and the
spindle (101).
NOTE: User can remove easily if using " "driver.
15. The sealing (129), the angular bearing (125) (2EA), the O-
ring (130) are assembled on the hub (105) with the floating
seal (102).
NOTE: Do not remove if not necessary.
In case of the removal, be careful not to scratch
using aluminum rod or hammer.
Disassembling Hydraulic motor Part
1. Remove the relief valve (2EA) from rear flange (1).
NOTE: Hexagon socket 32/ Torque wrench.
2. Remove hex. socket head bolts (43) from the rear flange
(1).
NOTE: Hexagon wrench 14.
3. Remove the rear flange (1) form the spindle (101).
4. Remove the spring (213) (10EA) form the rear flange (1).
NOTE: Remove rear flange (1) carefully after taken
using hands. Be carefully not to detach the
timimg plate (209) & the spring (213) if twisted
or beated by constraint.
Figure 29
θ
Figure 30
Figure 31
Figure 32

9. SP001621
Page 35
Travel Motor
5. Remove the paralell pin (42) from the spindle (101).
6. Remove the O-ring (126) from the spindle (101).
Do not reuse the O-ring (126).
NOTE: Do not reuse the O-ring (126).
7. Disassembling the rear flange (1) part
A. Remove the timing plate (9) from the rear flange (1).
NOTE: When removing the timing plate, user can
have difficulty of the removal due to the
close adhesion of rear flange (1) & oil.
Remove it after fitting a rod through the
hole which is used when a casting is
detached.
Be careful of the leakage due to both
surface scratch if using a sharp tool.
B. Remove the paralell pin (41) from the rear flange (1).
Figure 33
Figure 34
Figure 35
Figure 36

10. SP001621Travel Motor
Page 36
C. Remove the ball bearing (250) from the rear flange
(1).
8. Disassembling the spool
A. Remove two plugs (24) from the rear flange (1).
NOTE: Users can work easily if sub-disassembly
was done on the reversal table.
Hexagon socket 41 / Torque wrench.
B. Take out two springs[28], two stopper (c-3) from the
rear flange (1).
C. Remove the spool (23) from the rear flange (1).
NOTE: Be careful not to damage the outer
surface of the spool (23) and the sliding
surface of the rear flange (1).
Since the rear flange (1) and the spool
(23) are of the selective fitting type,
replace them together as a kit even if only
one of the two parts is damaged.
9. Disassembling the check valve
A. Remove two plugs (26) from the rear flange (1)
NOTE: Users can work easily if sub-disassembly
was done on the reversal table.
Hexagon wrench 14.
Figure 37
Figure 38
Figure 39
Figure 40

11. SP001621
Page 37
Travel Motor
B. Remove the spring (30) (2EA), valve (27) (2EA) from
rear flange (1).
10. Disassembling the two speed valve
A. Remove the plug (63) from the rear flange (1).
NOTE: Users can work easily if sub-disassembly
was done on the reversal table.
Hexagon wrench 10.
B. Remove the spool (65), spring (66) from rear flange
(1).
11. Disassembling the parking brake
A. Remove the piston (212) by injecting compressed air
from the parking brake access hole in the spindle
(101).
NOTE: Use the protection cover on the upper part
of spindle (101) when users put the
pressed air into suddenly.
Otherwise part damage & accident might
go on because the piston (212) is rushed
out of the spindle (101).
Figure 41
Figure 42
Figure 43
Figure 44

12. SP001621Travel Motor
Page 38
B. Remove the O-rings (235) (239), backup ring (247)
(248) from the piston (212).
NOTE: Do not reuse O-rings (235) (239), backup
ring (247) (248) after removal.
12. Disassembling the Hydraulic motor part
A. Lay the TM motor body on the side.
B. Drain out the oil from the TM motor.
NOTE: Place an oil receptacle under the TM
motor to receive the oil flowing out as the
motor is being laid on the side.
C. Hold the cylinder block (204) with both hands, and
remove it from the shaft (202).
NOTE: Before removal, hold the cylinder block
(204) with both hands and turn it two to
three times in a clockwise and a
counterclockwise direction alternately to
detach the shoe (206) from the swash
plate (203).
D. Remove the mating plates (216) and friction plates
(215) from the cylinder block (204).
NOTE: Be careful that if an attempt is made to
remove the cylinder block (204) without
detaching the shoe (206) from the swash
plate (203], then the piston, shoe and
other parts that are connected to the
cylinder block may come the cylinder
loose and fall into the spindle.
Figure 45
Figure 46
Figure 47

13. SP001621
Page 39
Travel Motor
13. Disassembling the cylinder block kit
A. Piston assembly (piston (205), shoe (206)) from the
removed cylinder block (204).
B. Piston (205), shoe (206) from the removed retainer
plate (207).
C. Thrust ball (208) from the removed cylinder block
(204).
D. Spring (214) (9ea) from the removed cylinder block
(204).
Figure 48
Figure 49
Figure 50
Figure 51

14. SP001621Travel Motor
Page 40
14. Remove swash plate (203) from the shaft (202).
15. Remove shaft (202) from the spindle (101).
NOTE: When seperating the swash plate, separate and
turn it by using hands to free from intervention
of the stopper.
16. Remove speed selector piston assembly (piston (261) and
shoe (262)) form the spindle (101) by feeding compressed
air from the access hole in spindle (101).
NOTE: Piston assembly - Piston (261) Shoe (262)
• Compressed air: 3 ~ 5 kgf/cm2
17. Remove paralell pin (242) pivot (267) from the spindle
(101).
18. Remove ball bearing (249) from the spindle (101)
NOTE: When piston (261) or shoe (262) is damaged,
if exchange is necessary, they have to be
exchanged together because the seperation is
impossible. Use the protection cover on the
upper part f spindle when users put the pressed
air into suddenly. Otherwise part damage &
accident might go on because the piston is
rushed out of the spindle.
19. Remove oil seal (232) from the spindle (101).
NOTE: Remove the oil seal (232) by hammering at the
circumference of the oil seal (232) using
driver.
Do not reuse the oil seal (232).
Figure 52
Figure 53
Figure 54
Figure 55
θ

15. SP001621
Page 41
Travel Motor
REASSEMBLY
General Precautions
1. Reassemble in a work area that is clean and free from dust
and drit.
2. Handle parts with bare hands to keep them free of linty
contaminants.
3. Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
4. Do not re-use o-ring, oil seal and floating seal that were
removed in disassembly.
5. Wash all parts throughly in a suitable solvent.
Dry throughly with compressed air.
Do not use the cloths.
6. When reassembling oil motor components of TM motor, be
sure to coat the sliding parts of the motor and valve with
fresh hydraulic oil. (NAS class 9 or above)
7. Use a torque wrench to tighten bolts and plugs, to the
torque specified as follows.
Reassembly Procedure
Reassemble the Hydraulic Motor Part
1. Install oil seal (232) into the oil seal hole of spindle (101).
NOTE: Apply lithium grease to the lip portion of oil seal
(232) position the sqarely over the bore of
spindle (101).
Figure 56

16. SP001621Travel Motor
Page 42
2. Install paralell pin (242) (2ea) and two speed piston
assembly (261) (262) into the spindle (101).
3. Install shaft (202) into the spindle (101).
NOTE: Assemble after applying grease on oil seal lip
(232).
4. Install pivot (267) (2ea) into the spindle (101).
5. Install swash plate(303) to the spindle (101).
NOTE: The swash plate (203) & the 2 speed stopper of
the spindle are interferenced. Install the swash
plate (203) after rotating. And then install it as
the regular position.
Figure 57
Figure 58
Figure 59
Figure 60

17. SP001621
Page 43
Travel Motor
6. Reassemble the cylinder block kit
A. Install spring (214) (9ea) to the cylinder block (204).
B. Install thrust ball (208) to the cylinder block (204).
C. Insert piston assembly (piston (205), shoe (206)) into
retainer plate (207).
NOTE: After mounting, immerse the entire them in
a working fluid.
D. Mount the piston assembly in the cylinder block
(204).
7. Install cylinder block (204) assembly to the shaft (202).
NOTE: After fitting splines of both cylinder block (204)
and shaft (202), assemble them.
After installing the cylinder (204), confirm
whether it revolves or not by turning using both
hands.
Motor is malfunction when it isn't revolve.
Figure 61
Figure 62
Figure 63
Figure 64

18. SP001621Travel Motor
Page 44
8. Reassemble the parking brake
A. Install mating plate (216) first and then a friction plate
(215), one by one, into the grooves of the outer
surface of the cylinder block (204).
NOTE: Immerse the friction plates (215) in a
working fluid before fitting them into the
grooves.
B. Install O-ring (275) (2ea) into the spindle (101).
C. Install two O-rings (235), (239) and two backup ring
(247), (248) in then O-ring grooves of the piston[212]
NOTE: Apply a thin coat of grease to the O-
rings (235) (239).
D. Mount a piston (212) in the spindle (101)
NOTE: If the piston[212] does not fit into the
spindle[101] because of the resistance of
the O-ring, tap the edge of the piston[212]
lightly and equally with a plastic hammer.
Be careful not to damage the O-ring and
backup ring at this time.
E. Insert a o-ring (126) into spindle (101).
F. Insert a paralell pin (42) (2ea) into spindle (101).
Figure 65
Figure 66
Figure 67
Figure 68

19. SP001621
Page 45
Travel Motor
Reassemble the Rear Flange Part (1)
1. Reassemble the check valve
A. Install O-ring (37) (2ea) on the plug (26) (2ea).
NOTE: Apply grease to the o-ring (37).
B. Install spring (30) and a valve (27) into the plug (26).
NOTE: Install a spring (30) and a valve (27) into
the plug (26), and then grease the spring
(30) and the valve (30) and hand-lock the
former.
C. Install plug (26) into the rear flange (1).
D. Install plug (26) in conjunction with the spring (30)
and the valve (30) into the rear flange (1), and tighten
the plug to the required torque.
– Tightening torque : 26 ± 4.0 kgf•m
NOTE: Adapter for hexagon wrench 14 /Torque
wrench
2. Reassemble the spool
A. Install spool (23) into the rear flange (1).
NOTE: Before installing the spool (23), apply
hydraulic oil to the spool. Be careful not
to damage the spool's surface & the inner
of rear flange (1).
B. Install O-ring (36) on the plug (24).
C. Install spring (28) and a stopper (c-3) into the plug
(24).
NOTE: Apply grease to the o-ring (36).
– Tightening torque : 45 ± 9 kgf•m
D. Install plug (24) into the rear flange (1).
NOTE: Exchange it as the rear flange KIT if the
exchange is necessary, because the rear
flange (301), the spool (323) insist of the
rear flange KIT.
– #41 socket/torque for hexagon wrench
Figure 69
Figure 70

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21. SP001621Travel Motor
Page 46
E. Tighten the plug (24) to the required torque.
3. Reassemble the two speed valve
A. Install O-rings (46) on plugs (63).
NOTE: Apply grease to the O-ring (46).
Apply hydraulic oil to the spool (65), while the
spool (65) is installed into the rear flange (1).
B. Insert a spool (65) and spring (66) into the rear flange
(1).
NOTE: Be careful not to damage the hole’s inner
of the rear flange (1) and the spool (65)
outer. It brings on low efficiency of the TM-
motor because of the leakage increase
after reassembling.
The shaft center should align with the hole
center because of little gap.
It is in order to protect the damage and
smooth assembling of the rear flange (1)
and the spool (65).
C. Insert a plug (63) into the rear flange (1).
– Tightening torque : 10 ± 2 kgf•m
– #10 adaptor/torquer wrench for hexagon
wrench
Figure 71
Figure 72
Figure 73

22. SP001621
Page 47
Travel Motor
4. Assembling of the rear flange’s inner parts
A. After installing the O-ring (74) on the plug (52), install
the steel ball (68), the plug (52) into the rear flange
(1).
NOTE: Apply grease to the O-ring (74).
Do not disassemble & assemble if not
necessary.
B. Install orifice (71), filter (79) into the rear flange (1).
Caulk it after assembling certainly.
NOTE: Do not disassemble & assemble if not
necessary.
5. Insert a ball bearing (250), timing plate (209), parallel pin
(41) (1ea) and spring (213) (12ea) into the rear flange (1).
NOTE: Be careful not so that the spring (213) & the
timing plate (209) should not separate from the
rear flange (1).
Apply hydraulic oil to the ball bearing (250).
Figure 74
Figure 75
Figure 76
Figure 77

23. SP001621Travel Motor
Page 48
6. Reassemble the rear flange (1) and spindle (101).
A. Mount the rear flange (1) on the spindle (101).
NOTE: When the rear flange (1) is mounted on
the spindle (101), fix the spring (13)
applied grease to not drop.
B. Tighten the socket bolt (43) into the spindle (101) to
the required torque.
– Tightening torque : 5.9 ± 1.0 kgf•m
– #14 adaptor/torque wrench for wrench
7. Tighten the relief valve into the rear flange[1] to the
required torque.
– Tightening torque : 25 ± 5 kgf•m
– #32 socket/torque for wrench
Figure 78
Figure 79
Figure 80
Figure 81